Serviceable Battery Pack Stanchion Sealing
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Solution Overview
Problem
Battery electric vehicle powertrains require a serviceable battery pack design that maintains sealing integrity while allowing for future maintenance and replacement of battery modules, as existing designs struggle to balance structural integration with independent subassembly serviceability.
Innovation Solution
An attachment system featuring a stanchion with flanges and threads, combined with gaskets and nuts, that compresses enclosure walls to create a sealed interface between the battery pack and its attachment structure, enabling secure mounting and easy disassembly for service, while maintaining environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the battery pack is sealed to prevent water and dirt intrusion, then environmental protection is improved, but serviceability for maintenance and replacement is worsened
Solution Approach 1:
The battery pack is divided into modular sections with individual enclosure walls that can be independently accessed through openings. Each opening is sealed with a gasket when closed, allowing the pack to remain sealed during operation while enabling selective access for service. The stanchion structure with flanges and nuts provides discrete attachment points that facilitate modular disassembly without compromising the overall sealing integrity.
Solution Approach 2:
The sealing system transitions from a static permanent seal to a dynamic reversible seal. Gaskets are designed to maintain sealing when the battery pack is assembled and secured with nuts, but allow for controlled disassembly when service is needed. The seal between the enclosure wall and attachment structure can be engaged or disengaged as required, providing adaptability between sealed operation mode and serviceable mode.
2Stability of the object's composition
If the battery pack is integrated with the vehicle structure, then structural stability is improved, but independent serviceability is worsened
Solution Approach 1:
The attachment system uses discrete stanchions with flanges and nuts at specific locations rather than continuous integration. This segmented approach allows the battery pack to be firmly attached to the vehicle structure for stability during operation, while enabling independent removal of the battery pack or individual modules for service by simply loosening the nuts and detaching the stanchions.
Solution Approach 2:
The stanchion structure serves multiple functions: it provides structural attachment to the vehicle for stability, creates sealed openings in the enclosure walls, and facilitates independent removal for service. The same attachment mechanism that secures the battery pack during operation becomes the release mechanism for serviceability, eliminating the need for separate integration and service systems.
3Reliability
If the enclosure wall is compressed to create a sealed interface, then sealing integrity is improved, but disassembly capability is worsened
Solution Approach 1:
The compression sealing system is designed to be dynamic rather than permanent. Nuts secure the flanges to compress gaskets and create sealed interfaces during operation, but can be easily loosened and removed for disassembly. The seal between the enclosure wall and attachment structure engages under compression during assembly but allows controlled separation when the fastening elements are released, maintaining reliability during operation while enabling serviceability.
Solution Approach 2:
Gaskets serve as intermediary elements between the flanges and enclosure walls. These compressible seals create the tight interface needed for sealing integrity during operation, but their elastic properties allow them to maintain the seal under compression while permitting clean separation when the fastening force is removed. The gasket acts as a mediator that enables both strong sealing and easy disassembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for leak-tight assembly and disassembly of battery packs, ensuring environmental protection and facilitating maintenance, such as replacing battery modules during the vehicle's service life, without compromising structural integrity or sealing.
Implementation Method 1
a first gasket trapped between the first flange and the inner side of the first enclosure wall
Implementation Method 2
a first nut engaging the first set of threads and configured to compress the first enclosure wall between the first nut and the first flange
Implementation Method 3
a threaded attachment fastener configured to draw the stanchion and the battery pack attachment structure together
Data Source
AI summary
An serviceable battery pack and assembly method may include a battery pack having a stanchion extending through a wall of the battery pack, a first battery pack seal between the stanchion and the wall of the battery pack, attachment of the battery pack at the exterior of a floor pan of a vehicle at the stanchion, and a second battery pack seal between the exterior of the floor pan and the wall of the battery pack surrounding the stanchion.